Manufacturing execution system (MES) and methods of monitoring glycol manufacturing processes utilizing functional nanomaterials

ABSTRACT

A Manufacturing Execution System (MES) and related methods of monitoring a glycol manufacturing processes are disclosed herein. The methods are useful to provide a plurality of analysis to the glycol manufacturing process. Consequently, the manufacturing execution system and methods provide a means to perform validation and quality manufacturing on an integrated level whereby glycol manufacturers can achieve data and product integrity and ultimately minimize cost.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Ser. No. 11/715,627, filed 8Mar. 2007. The contents of which are fully incorporated by reference.

STATEMENT OF RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSOREDRESEARCH

Not applicable.

FIELD OF THE INVENTION

The invention described herein relates to the field of pharmaceuticalmanufacturing and nanotechnologies. Specifically, methods of interfacingnanomaterials with software programs used for the monitoring andexecution of pharmaceutical manufacturing processes. The inventionfurther relates to the enhancement of nanotechnologies to produce higherquality more efficient drugs.

BACKGROUND OF THE INVENTION

Previously we have described novel methods, systems, software programs,and manufacturing execution systems for validation, quality and riskassessment, and monitoring of pharmaceutical manufacturing processes.See, US2005/0251278 published 10 Nov. 2005; US2006/0276923 published 7Dec. 2006; US2006/0271227 Published 30 Nov. 2006; US2007/0021856Published 25 Jan. 2007; and US2007/0032897 Published 8 Feb. 2007.Additionally, we endeavor to further the state of the art using softwareand computer programming in the field of nanotechnology andsupramolecular electronics.

Nanotechnology is a field of applied science and technology covering abroad range of topics. The main unifying theme is the control of matteron a scale smaller than one micrometer as well as the fabrication ofdevices on this same length scale. Worldwide research is currently beingconducted in countless areas to discover new and useful areas wherenanotechnology can be exploited commercially. The research involvespotential utility in industrial applications, such as pharmaceuticalmanufacturing as well as other areas of medicine and bioenergy just toname a few.

Despite the apparent simplicity of this definition, nanotechnologyactually encompasses diverse lines of inquiry. Nanotechnology cutsacross many disciplines, including colloidal science, chemistry, appliedphysics, biology. It could variously be seen as an extension of existingsciences into the nanoscale, or as a recasting of existing sciencesusing a newer, more modern term.

Two main approaches are used in nanotechnology. One is a “bottom-up”approach where materials and devices are built from molecular componentswhich assemble themselves chemically using principles of molecularrecognition. The other being a “top-down” approach where nano-objectsare constructed from larger entities without atomic-level control.Nanomaterials are materials having unique properties arising from theirnanoscale dimensions. The use of nanoscale materials can also be usedfor bulk applications. In fact, most present commercial applications ofnanotechnology are of this flavor.

Nanomaterials from a “top-down” design have certain scaling deficiencieswhich must be assessed. For example, A number of physical phenomenabecome noticeably pronounced as the size of the system decreases. Theseinclude statistical mechanical effects, as well as quantum mechanicaleffects, for example the “quantum size effect” where the electronicproperties of solids are altered with great reductions in particle size.This effect does not come into play by going from macro to microdimensions. However, it becomes dominant when the nanometer size rangeis reached. Additionally, a number of physical properties change whencompared to macroscopic systems. One example is the increase in surfacearea to volume of materials. This catalytic activity also openspotential risks in their interaction with biomaterials.

Additionally, materials reduced to the nanoscale can suddenly show verydifferent properties compared to what they exhibit on a macroscale,enabling unique applications. For instance, opaque substances becometransparent (copper); inert materials become catalysts (platinum);stable materials turn combustible (aluminum); solids turn into liquidsat room temperature (gold); insulators become conductors (silicon) toname a few.

Additionally, nanosize powder particles are important for theachievement of uniform nanoporosity and similar applications. However,the tendency of small particles to form clumps (“agglomerates”) is aserious technological problem that impedes such applications.

Another deficiency is that the volume of an object decreases as thethird power of its linear dimensions, but the surface area onlydecreases as its second power. This somewhat subtle and unavoidableprinciple has huge ramifications. For example the power of a drill (orany other machine) is proportional to the volume, while the friction ofthe drill's bearings and gears is proportional to their surface area.For a normal-sized drill, the power of the device is enough to handilyovercome any friction. However, scaling its length down by a factor of1000, for example, decreases its power by 1000³ (a factor of a billion)while reducing the friction by only 1000² (a factor of “only” amillion). Proportionally it has 1000 times less power per unit frictionthan the original drill. If the original friction-to-power ratio was,say, 1%, that implies the smaller drill will have 10 times as muchfriction as power. The drill is useless.

This is why, while super-miniature electronic integrated circuits can bemade to function, the same technology cannot be used to make functionalmechanical devices in miniature.

Nanomaterials from a “bottom-up” design also have certain deficiencieswhich must be assessed. Modern synthetic chemistry has reached the pointwhere it is possible to prepare small molecules to almost any structure.These methods are used today to produce a wide variety of usefulchemicals such as pharmaceuticals or commercial polymers. However, theability of this to extend into supramolecular assemblies consisting ofmany molecules arranged in a well defined manner is problematic. Suchbottom-up approaches should, broadly speaking, be able to producedevices in parallel and much cheaper than top-down methods. However,most useful structures require complex and thermodynamically unlikelyarrangements of atoms. The basic laws of probability and entropy make itvery unlikely that atoms will “self-assemble” in useful configurations,or can be easily and economically nudged to do so. About the onlyexample of this is crystal-growing, for which Nanotechnology cannot takeany credit.

Given the deficiencies associated with “top-down” and “bottom-up”nanomaterials, it becomes clear that providing a functional approach tonanotechnology (i.e. the development of nanomaterials of a desiredfunctionality) can be problematic.

Finally, implementing nanotechnologies in highly-regulated bulkmanufacturing applications, such as pharmaceutical manufacturing, onlycompounds problems. The present invention overcomes these problems.

SUMMARY OF THE INVENTION

The invention provides for nanomaterials with functional characteristicsthat can be interfaced with software programs designed for use in thepharmaceutical manufacturing process. Specifically, software programsthat monitor quality control and the quality process used in themanufacture, processing, and storing of drugs. As used herein, the term“drug” is synonymous with “pharmaceutical”. In certain embodiments, thenanomaterial is used in membrane analysis to ensure purity andconsistency of an ingredient used in a pharmaceutical manufacturingprocess.

The invention further comprises a nanomaterial that is used to analyzesurface derivations on pharmaceuticals and biosensors used in thepharmaceutical manufacturing process.

In certain embodiments, the nanomaterial is used in tribo-technicalanalysis to characterize friction, lubrication, and wearing effects onmaterials as a result of a pharmaceutical manufacturing process.

In certain embodiments, the nanomaterial is used in morphology analysisto characterize texture and/or roughness effects of materials as aresult of a pharmaceutical manufacturing process.

In certain embodiments, the nanomaterial is used in analysis ofmechanical properties to characterize hardness, elasticity, and/orcompressibility properties of materials as a result of a pharmaceuticalmanufacturing process.

In certain embodiments, the nanomaterial is used in porosity analysis ofmaterials as a result of a pharmaceutical manufacturing process.

In certain embodiments, the nanomaterial is used in permeabilityanalysis of materials as a result of a pharmaceutical manufacturingprocess.

In certain embodiments, the nanomaterial is used in absorption analysisof materials as a result of a pharmaceutical manufacturing process.

In certain embodiments, the nanomaterial is used in purificationanalysis of materials as a result of a pharmaceutical manufacturingprocess.

In certain embodiments, the nanomaterial is used in the visualizationanalysis of materials as a result of a pharmaceutical manufacturingprocess.

Based on the foregoing non-limiting exemplary embodiments, the softwareprogram can be interfaced with the nanomaterial to monitor qualityassurance protocols put in place by the quality control unit.

The invention further provides interfacing a software program with afunctional nanomaterial whereby the nanomaterial is useful in measuringmanufacturing parameters used in pharmaceutical manufacture.

The invention further comprises a nanomaterial system which integratesapplication software and methods disclosed herein to provide acomprehensive validation and quality assurance protocol that is used bya plurality of end users whereby the data compiled from the system isanalyzed and used to determine is quality assurance protocols andvalidation protocols are being achieved.

The invention further comprises implementing the nanomaterial andsoftware program to multiple product lines whereby simultaneousproduction lines are monitored using the same system.

The invention further comprises implementation of the nanomaterial andsoftware program described herein into the crystallization process, thetablet press process, the chromatography process, the pH monitoringprocess, the liquid mixing process, the powder blending process, thewater-for-injection systems, the water purification systems, the cellculture systems, and the finishing and packaging systems subset of thepharmaceutical manufacturing process whereby the data compiled by thesubset processes is tracked continuously overtime and said data is usedto analyze the subset processes and whereby said data is integrated andused to analyze the quality control process of the pharmaceuticalmanufacturing process at-large.

The invention further comprises a manufacturing execution system, whichcontrols the pharmaceutical manufacturing process and increasesproductivity and improves quality of pharmaceuticals by interfacing thesoftware program with a nanomaterial.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1. Schematic of a hybrid approach to interfacing nanomaterials tosoftware programs. As shown in the figure, the left side shows asoftware program that is designed with a top-down design. The right sideshows a nanomaterial that is designed with a bottom-up design. Thesoftware program and nanomaterials are interfaced to operate on theelectrical level like conventional computing devices. The interfacednanomaterials are then integrated into the pharmaceutical manufacturingprocess.

FIG. 2. Schematic of manufacturing execution system. As shown in FIG. 4,each process in the pharmaceutical manufacturing system is integratedwith a computer product and data is monitored assessing various factors,the parameters of which are set forth by the quality control unit. Thespecific systems are then cumulatively integrated by the quality controlunit and a data record is made. The data record is maintained and usedto determine risk factors and make quality assessments.

FIG. 3. Membrane analysis performed on a crystallization process used inpharmaceutical manufacturing. Ingredient X is blended with ingredient Yand filtered. The nanomaterial is scanned across the filtration membraneon a continuous basis. The quality parameters for the membrane aredetermined by the quality control unit. The membrane analysis detects amembrane failure. The membrane is replaced.

FIG. 4. Surface deviation analysis on a tablet press process used inpharmaceutical manufacturing. Tablets are manufactured and arecontinuously monitored. Nanomaterials scan the surface of the tabletsfor surface deviations associated with the tablet press process. Thequality parameters are determined by a quality control unit. Upon thedetection of a deviation outside the scope of the quality parameters, afailure analysis occurs. Corrective action is taken and the defectivetablets are taken out of the manufacturing process.

FIG. 5. Schematic of a chromatography system whereby the nanomaterialprovides a tribo-technical analysis of an active ingredient used tomanufacture pharmaceuticals. Nanomaterials scan the surface of thematerials to assess morphology, roughness, or characterizationassociated with the chromatography process. The quality parameters aredetermined by a quality control unit. Upon the detection of a deviationoutside the scope of the quality parameters, a failure analysis occurs.Corrective action is taken and the defective materials are taken out ofthe manufacturing process.

FIG. 6. Schematic of a filtration/purification process interfaced withnanomaterial. Material is fed through the input and filtered/purified.Nanomaterials monitor the materials for conformance with qualityparameters. The quality parameters are determined by a quality controlunit. Upon the detection of a deviation outside the scope of the qualityparameters, a failure analysis occurs. Corrective action is taken andthe defective materials are taken out of the manufacturing process.

FIG. 7. Schematic of a nanomaterial interfaced with a downstreamprocessing system used in pharmaceutical manufacturing. The nanomaterialis interfaced with the Removal step, the product isolation step, theproduct purification step, and the product polishing step. The data ismonitored and collected for conformance with quality parameters. Thequality parameters are determined by a quality control unit. Upon thedetection of a deviation outside the scope of the quality parameters, afailure analysis occurs. Corrective action is taken and the defectivematerials are taken out of the manufacturing process.

DETAILED DESCRIPTION OF THE INVENTION Outline of Sections

I.) Definitions

II.) Nanomaterial

-   -   a. Functional Properties of Nanomaterial        -   i. Nanomaterial with Thermal Conductivity        -   ii. Nanomaterial with Porosity/Permeability        -   iii. Nanomaterial with enhanced luminescence        -   iv. Nanomaterial with enhanced acoustics        -   v. Nanomaterial with magnetic properties        -   vi. Nanomaterial with enhanced solubility        -   vii. Shape Engineered nanomaterials        -   viii. Nanomaterials with enhanced optical properties

III.) Sensors

IV.) Software Program and Computer Product

V.) Analysis

VI.) Manufacturing Execution System (“MES”)

VII.) KITS/Articles of Manufacture

I.) DEFINITIONS

Unless otherwise defined, all terms of art, notations and otherscientific terms or terminology used herein are intended to have themeanings commonly understood by those of skill in the art to which thisinvention pertains unless the context clearly indicates otherwise. Insome cases, terms with commonly understood meanings are defined hereinfor clarity and/or for ready reference, and the inclusion of suchdefinitions herein should not necessarily be construed to represent asubstantial difference over what is generally understood in the art.Many of the techniques and procedures described or referenced herein arewell understood and commonly employed using conventional methodology bythose skilled in the art, such as, for example, the widely utilizedcurrent Good Manufacturing Practice guidelines.

As used herein the terms “drug” and “pharmaceutical” include veterinarydrugs and human drugs, including human biological drug products.

“Nanomaterial” means a material in any dimensional form (zero, one, two,three) and domain size less than 100 nanometers.

“Nanostructure” means a structure having at least one dimension that isless than 500 nanometers. Examples, include but are not limited tonanocrystals, nanocomposites, nanograins, nanotubes, nanoceramics, andnanopowders.

“nanocrystal” means nanostructures that are substantiallymonocrystalline. A nanocrystal has at least one region or characteristicdimension with a dimension of less than about 500 nm, and down to on theorder of less than about 1 nm. As used herein, when referring to anynumerical value, “about” means a value of .+−.10% of the stated value(e.g. about 100 nm encompasses a range of sizes from 90 nm to 110 nm,inclusive). The terms “nanocrystal,” “nanodot,” “dot” and “quantum dot”are readily understood by the ordinarily skilled artisan to representlike structures and are used herein interchangeably. The presentinvention also encompasses the use of polycrystalline or amorphousnanocrystals.

“aspect ratio” means the ratio of the maximum to the minimum dimensionof a particle.

“biomaterial” (a.k.a. biological material) may refer to biologicalmatter, biomass, biomolecule, and organic material (i.e. derived fromliving things or containing carbon).

“Integrated circuits (IC)” means a miniaturized electronic circuit thathas been manufactured in the surface of a thin substrate ofsemiconductor material.

“hybrid integrated circuit” means a miniaturized electronic circuitbonded to a substrate or circuit board.

“nanowire” means a wire of dimensions of the order of a nanometer (10⁻⁹meters). Alternatively, nanowires can be defined as structures that havea lateral size constrained to tens of nanometers or less and anunconstrained longitudinal size. Nanowires include metallic (e.g., Ni,Pt, Au), semiconducting (e.g., InP, Si, GaN, etc.), and insulating(e.g., SiO₂, TiO₂). Molecular nanowires are composed of repeatingmolecular units either organic (e.g. DNA) or inorganic (e.g.Mo₆S_(9-x)I_(x)).

“domain size” means the minimum dimension of a particular materialmorphology. In the case of powders, the domain size is the grain size.In the case of whiskers and fibers, the domain size is the diameter. Inthe case of plates and films, the domain size is the thickness.

“nanopowder” (a.k.a. “nanosize powders,” “nanoparticles,” and “nanoscalepowders”) means and refer to fine powders that have a mean size lessthan 250 nanometers. For example, in some embodiments, the nanopowdersare powders that have particles with a mean domain size less than 100nanometers and with an aspect ratio ranging from 1 to 1,000,000. Purepowders, as the term used herein, are powders that have compositionpurity of at least 99.9% by metal basis. For example, in someembodiments the preferred purity is 99.99%.

“Powder” (a.k.a. “powder”, “particle”, and “grain”) are usedinterchangeably and encompass oxides, carbides, nitrides, borides,chalcogenides, halides, metals, intermetallics, ceramics, polymers,alloys, and combinations thereof. These terms include single metal,multi-metal, and complex compositions. These terms further includehollow, dense, porous, semi-porous, coated, uncoated, layered,laminated, simple, complex, dendritic, inorganic, organic, elemental;non-elemental, composite, doped, undoped, spherical, non-spherical,surface functionalized, surface non-functionalized, stoichiometric, andnon-stoichiometric forms or substances. Further, the term powder in itsgeneric sense includes one-dimensional materials (fibers, tubes, etc.),two-dimensional materials (platelets, films, laminates, planar, etc.),and three-dimensional materials (spheres, cones, ovals, cylindrical,cubes, monoclinic, parallelolipids, dumbbells, hexagonal, truncateddodecahedron, irregular shaped structures, etc.). The term metal usedabove includes any alkali metal, alkaline earth metal, rare earth metal,transition metal, semi-metal (metalloids), precious metal, heavy metal,radioactive metal, isotopes, amphoteric element, electropositiveelement, cation forming element, and includes any current or futurediscovered element in the periodic table.

“Precursor” means any raw substance that can be transformed into apowder of same or different composition. In certain embodiments, theprecursor is a liquid. The term precursor includes, but is not limitedto, organometallics, organics, inorganics, solutions, dispersions,melts, sols, gels, emulsions, or mixtures.

“nanofiller” (a.k.a. nanostructured filler) means a structure orparticle intimately mixed with a matrix to form a nanostructuredcomposite. At least one of the nanostructured filler and thenanostructured composite has a desired material property which differsby at least 20% from the same material property for a micron-scalefiller or a micron-scale composite, respectively. The desired materialproperty is selected from the group consisting of refractive index,transparency to light, reflection characteristics, resistivity,permittivity, permeability, coercivity, B-H product, magnetichysteresis, breakdown voltage, skin depth, curie temperature,dissipation factor, work function, band gap, electromagnetic shieldingeffectiveness, radiation hardness, chemical reactivity, thermalconductivity, temperature coefficient of an electrical property, voltagecoefficient of an electrical property, thermal shock resistance,biocompatibility and wear rate. The nanostructured filler may compriseone or more elements selected from the s, p, d, and f groups of theperiodic table, or it may comprise a compound of one or more suchelements with one or more suitable anions, such as aluminum, antimony,boron, bromine, carbon, chlorine, fluorine, germanium, hydrogen, indium,iodine, nickel, nitrogen, oxygen, phosphorus, selenium, silicon, sulfur,or tellurium. The matrix may be a polymer (e.g., poly(methylmethacrylate), poly(vinyl alcohol), polycarbonate, polyalkene, orpolyaryl), a ceramic (e.g., zinc oxide, indium-tin oxide, hafniumcarbide, or ferrite), or a metal (e.g., copper, tin, zinc, or iron).Loadings of the nanofiller may be as high as 95%, although loadings of80% or less are preferred. The invention also comprises devices whichincorporate the nanofiller (e.g., electrical, magnetic, optical,biomedical, and electrochemical devices).

“coating” (a.k.a. “film”, “laminate”, or “layer”) means any depositioncomprising submicron and nanoscale powders. The term includes in itsscope a substrate, surface, deposition, or a combination thereof havinga hollow, dense, porous, semi-porous, coated, uncoated, simple, complex,dendritic, inorganic, organic, composite, doped, undoped, uniform,non-uniform, surface functionalized, surface non-functionalized, thin,thick, pretreated, post-treated, stoichiometric, or non-stoichiometricform or morphology.

“agglomerated” means a powder in which at least some individualparticles of the powder adhere to neighboring particles, primarily byelectrostatic forces.

“aggregated” means a powder in which at least some individual particlesare chemically bonded to neighboring particles.

“supramolecular electronics” means the assemblies of pi-conjugatedsystems on the 5 to 100 nanometer length scale that are prepared byself-assembly with the aim to fit these structures between electrodes.

“atomic force microscope (“AFM”)” means a very high-resolution type ofscanning probe microscope, with demonstrated resolution of fractions ofan Angstrom, more than 1000 times better than the optical diffractionlimit. The AFM is one of the foremost tools for imaging, measuring andmanipulating matter at the nanoscale.

“scanning tunneling microscope (“STM”)” means a non-optical microscopethat scans an electrical probe over a surface to be imaged to detect aweak electric current flowing between the tip and the surface. The STMallows visualize regions of high electron density and hence infer theposition of individual atoms and molecules on the surface of a lattice.The STM is capable of higher resolution than the atomic force microscope(AFM)

“biosensor” means a device for the detection of an analyte that combinesa biological component with a physicochemical detector component. Abiosensor comprises three parts: (i) a sensitive biological element(i.e. biological material, including but not limited to, tissue,microorganisms, organelles, cell receptors, enzymes, antibodies, nucleicacids, amino acids, etc) or a biologically derived material or biomimic;(ii) a transducer; (iii) a detector element (i.e. chemical,physiochemical, optical, piezoelectric, electrochemical; thermometric,or magnetic).

“optical biosensor” means a biosensor that utilizes the behavior andproperties of light and the interaction of light with matter as thedetector element.

“optical switch” means a switch that enables signals in optical fibersor integrated optical circuits (IOCs) to be selectively switched fromone circuit to another.

“interface” means the communication boundary between two or moreentities, such as a piece of software, a hardware device, or a user. Itgenerally refers to an abstraction that an entity provides of itself tothe outside. This separates the methods of external communication frominternal operation, and allows it to be internally modified withoutaffecting the way outside entities interact with it, as well as providemultiple abstractions of itself. It may also provide a means oftranslation between entities which do not speak the same language, suchas between a human and a computer. The interface between a human and acomputer is called a user interface. Interfaces between hardwarecomponents are physical interfaces. Interfaces between software existbetween separate software components and provide a programmaticmechanism by which these components can communicate.

“pi-conjugated systems” (a.k.a. “stacking”) means the noncovalentinteraction between organic compounds containing aromatic moieties. π-πinteractions are caused by intermolecular overlapping of p-orbitals inπ-conjugated systems, so they become stronger as the number ofπ-electrons increases.

“quantum dots” means a semiconductor nanostructure that confines themotion of conduction band electrons, valence band holes, or excitons(pairs of conduction band electrons and valence band holes) in all threespatial directions. The confinement can be due to electrostaticpotentials (generated by external electrodes, doping, strain,impurities), due to the presence of an interface between differentsemiconductor materials (e.g. in the case of self-assembled quantumdots), due to the presence of the semiconductor surface (e.g. in thecase of a semiconductor nanocrystal), or due to a combination of these.A quantum dot has a discrete quantized energy spectrum.

“molecular self-assembly” means the assembly of molecules withoutguidance or management from an outside source.

“nanocomposite” means materials that are created by introducingnanoparticulates into a macroscopic sample material. The nanomaterialsadd to the electrical and thermal conductivity as well as to themechanical strength properties of the original material. In general, thenanomaterial used are carbon nanotubes and they are dispersed into theother composite materials during processing. The percentage by weight ofthe nanomaterials introduced is able to remain very low (on the order of0.5%-5%) due to the incredibly high surface area to volume ratio of theparticles.

“molecular electronics” (a.k.a. moletronics) means an interdisciplinarythemed materials science in which the unifying feature is the use ofmolecular building blocks for the fabrication of electronic components,both passive (e.g. resistive wires) and active (e.g transistors).Molecular electronics provides a means to extend Moore's Law beyond theforeseen limits of small-scale conventional silicon integrated circuits.

“Moore's law” means the empirical observation made in 1965 that thenumber of transistors on an integrated circuit for minimum componentcost doubles every 24 months. It is attributed to Gordon E. Moore (born1929), a co-founder of Intel.

“supramolecular chemistry” means the area of chemistry which focuses onthe noncovalent bonding interactions of molecules. Traditional organicsynthesis involves the making and breaking of covalent bonds toconstruct a desired molecule.

“molecular recognition” means a chemical event in which a host moleculeis able to form a complex with a second molecule (i.e. the guest). Thisprocess occurs through non-covalent chemical bonds, including but notlimited to, hydrogen bonding, hydrophobic interactions, ionicinteraction.

“static molecular recognition” means a 1:1 type complexation reactionbetween a host molecule and a guest molecule (an analogy is theinteraction between a key and a keyhole.) To achieve advanced staticmolecular recognition, it is necessary to make recognition sites thatare specific for guest molecules.

“dynamic molecular recognition” means a reaction that dynamicallychanges the equilibrium to an n:m type host-guest complex by arecognition guest molecule. Dynamic molecular recognition appearing insupermolecules is essential for designing highly functional chemicalsensors and molecular devices.

“rotaxane” means a mechanically-interlocked molecular architectureconsisting of a dumbbell-shaped molecule that is threaded through amacrocycle or ring-like molecule. The two components are kineticallytrapped as the two end-groups of the dumbbell (often called stoppers)are larger than the internal diameter of the ring, and thus preventdissociation (unthreading) since this would require significantdistortion of the covalent bonds. The name, rotaxane, is derived fromthe Latin for wheel (rota) and axle (axis).

“synthetic molecular motors” means nanoscale devices capable of rotationunder energy input. The basic requirements for a synthetic motor arerepetitive 360° motion, the consumption of energy, and unidirectionalrotation. Examples include but are not limited to triptycence motors andhelicene.

“abstraction” means the separation of the logical properties of data orfunction from its implementation in a computer program.

“access time” means the time interval between the instant at which acall for data is initiated and the instant at which the delivery of thedata is completed.

“adaptive maintenance” means software maintenance performed to make acomputer program usable in a changed environment.

“algorithm” means any sequence of operations for performing a specifictask.

“algorithm analysis” means a software verification and validation(“V&V”) task to ensure that the algorithms selected are correct,appropriate, and stable, and meet all accuracy, timing, and sizingrequirements.

“analog” means pertaining to data [signals] in the form of continuouslyvariable [wave form] physical quantities; e.g., pressure, resistance,rotation, temperature, voltage.

“analog device” means a device that operates with variables representedby continuously measured quantities such as pressures, resistances,rotations, temperatures, and voltages.

“analog-to-digital converter” means input related devices whichtranslate an input device's [sensor] analog signals to the correspondingdigital signals needed by the computer.

“analysis” means a course of reasoning showing that a certain result isa consequence of assumed premises.

“application software” means software designed to fill specific needs ofa user.

“bar code” means a code representing characters by sets of parallel barsof varying thickness and separation that are read optically bytransverse scanning.

“basic input/output system” means firmware that activates peripheraldevices in a PC. Includes routines for the keyboard, screen, disk,parallel port and serial port, and for internal services such as timeand date. It accepts requests from the device drivers in the operatingsystem as well from application programs. It also contains autostartfunctions that test the system on startup and prepare the computer foroperation. It loads the operating system and passes control to it.

“batch processing” means execution of programs serially with nointeractive processing.

“benchmark” means a standard against which measurements or comparisonscan be made.

“block” means a string of records, words, or characters that fortechnical or logical purposes are treated as a unity.

“block check” means the part of the error control procedure that is usedfor determining that a block of data is structured according to givenrules.

“block diagram” means a diagram of a system, instrument or computer, inwhich the principal parts are represented by suitably annotatedgeometrical figures to show both the basic functions of the parts andthe functional relationships between them.

“blueprint” means an detailed plan or outline.

“boot” means to initialize a computer system by clearing memory andreloading the operating system. A distinction can be made between a warmboot and a cold boot. A cold boot means starting the system from apowered-down state. A warm boot means restarting the computer while itis powered-up. Important differences between the two procedures are; 1)a power-up self-test, in which various portions of the hardware [such asmemory] are tested for proper operation, is performed during a cold bootwhile a warm boot does not normally perform such self-tests, and 2) awarm boot does not clear all memory.

“bootstrap” means a short computer program that is permanently residentor easily loaded into a computer and whose execution brings a largerprogram, such an operating system or its loader, into memory.

“boundary value” means a data value that corresponds to a minimum ormaximum input, internal, or output value specified for a system orcomponent.

“boundary value analysis” means a selection technique in which test dataare chosen to lie along “boundaries” of the input domain [or outputrange] classes, data structures, procedure parameters, etc.

“branch analysis” means a test case identification technique whichproduces enough test cases such that each decision has a true and afalse outcome at least once.

“calibration” means ensuring continuous adequate performance of sensing,measurement, and actuating equipment with regard to specified accuracyand precision requirements.

“certification” means technical evaluation, made as part of and insupport of the accreditation process that establishes the extent towhich a particular computer system or network design and implementationmeet a pre-specified set of requirements.

“change control” means the processes, authorities for, and procedures tobe used for all changes that are made to the computerized system and/orthe system's data. Change control is a vital subset of the QualityAssurance [QA] program within an establishment and should be clearlydescribed in the establishment's SOPs.

“check summation” means a technique for error detection to ensure thatdata or program files have been accurately copied or transferred.

“compiler” means computer program that translates programs expressed ina high-level language into their machine language equivalents.

“computer system audit” means an examination of the procedures used in acomputer system to evaluate their effectiveness and correctness and torecommend improvements.

“computer system security” means the protection of computer hardware andsoftware from accidental or malicious access, use, modification,destruction, or disclosure.

“concept phase” means the initial phase of a software developmentproject, in which user needs are described and evaluated throughdocumentation.

“configurable, off-the-shelf software” means application software,sometimes general purpose, written for a variety of industries or usersin a manner that permits users to modify the program to meet theirindividual needs.

“control flow analysis” means a software V&V task to ensure that theproposed control flow is free of problems, such as design or codeelements that are unreachable or incorrect.

“controller” means hardware that controls peripheral devices such as adisk or display screen. It performs the physical data transfers betweenmain memory and the peripheral device.

“conversational” means pertaining to a interactive system or mode ofoperation in which the interaction between the user and the systemresembles a human dialog.

“coroutine” means a routine that begins execution at the point at whichoperation was last suspended, and that is not required to return controlto the program or subprogram that called it.

“corrective maintenance” means maintenance performed to correct faultsin hardware or software.

“critical control point” means a function or an area in a manufacturingprocess or procedure, the failure of which, or loss of control over, mayhave an adverse affect on the quality of the finished product and mayresult in an unacceptable health risk.

“data analysis” means evaluation of the description and intended use ofeach data item in the software design to ensure the structure andintended use will not result in a hazard. Data structures are assessedfor data dependencies that circumvent isolation, partitioning, dataaliasing, and fault containment issues affecting safety, and the controlor mitigation of hazards.

“data integrity” means the degree to which a collection of data iscomplete, consistent, and accurate.

“data validation” means a process used to determine if data areinaccurate, incomplete, or unreasonable. The process may include formatchecks, completeness checks, check key tests, reasonableness checks andlimit checks.

“design level” means the design decomposition of the software item;e.g., system, subsystem, program or module.

“design phase” means the period of time in the software life cycleduring which the designs for architecture, software components,interfaces, and data are created, documented, and verified to satisfyrequirements.

“diagnostic” means pertaining to the detection and isolation of faultsor failures.

“different software system analysis” means Analysis of the allocation ofsoftware requirements to separate computer systems to reduce integrationand interface errors related to safety. Performed when more than onesoftware system is being integrated.

“dynamic analysis” means analysis that is performed by executing theprogram code.

“encapsulation” means a software development technique that consists ofisolating a system function or a set of data and the operations on thosedata within a module and providing precise specifications for themodule.

“end user” means a person, device, program, or computer system that usesan information system for the purpose of data processing in informationexchange.

“error detection” means techniques used to identify errors in datatransfers.

“error guessing” means the selection criterion is to pick values thatseem likely to cause errors.

“error seeding” means the process of intentionally adding known faultsto those already in a computer program for the purpose of monitoring therate of detection and removal, and estimating the number of faultsremaining in the program.

“failure analysis” means determining the exact nature and location of aprogram error in order to fix the error, to identify and fix othersimilar errors, and to initiate corrective action to prevent futureoccurrences of this type of error.

“Failure Modes and Effects Analysis” means a method of reliabilityanalysis intended to identify failures, at the basic component level,which have significant consequences affecting the system performance inthe application considered.

“FORTRAN” means an acronym for FORmula TRANslator, the first widely usedhigh-level programming language. Intended primarily for use in solvingtechnical problems in mathematics, engineering, and science.

“life cycle methodology” means the use of any one of several structuredmethods to plan, design, implement, test and operate a system from itsconception to the termination of its use.

“logic analysis” means evaluates the safety-critical equations,algorithms, and control logic of the software design.

“low-level language” means the advantage of assembly language is that itprovides bit-level control of the processor allowing tuning of theprogram for optimal speed and performance. For time critical operations,assembly language may be necessary in order to generate code whichexecutes fast enough for the required operations.

“maintenance” means activities such as adjusting, cleaning, modifying,overhauling equipment to assure performance in accordance withrequirements.

“modulate” means varying the characteristics of a wave in accordancewith another wave or signal, usually to make user equipment signalscompatible with communication facilities.

“Pascal” means a high-level programming language designed to encouragestructured programming practices.

“path analysis” means analysis of a computer program to identify allpossible paths through the program, to detect incomplete paths, or todiscover portions of the program that are not on any path.

“quality assurance” means the planned systematic activities necessary toensure that a component, module, or system conforms to establishedtechnical requirements.

“quality control” means the operational techniques and procedures usedto achieve quality requirements.

“software engineering” means the application of a systematic,disciplined, quantifiable approach to the development, operation, andmaintenance of software.

“software engineering environment” means the hardware, software, andfirmware used to perform a software engineering effort.

“software hazard analysis” means the identification of safety-criticalsoftware, the classification and estimation of potential hazards, andidentification of program path analysis to identify hazardouscombinations of internal and environmental program conditions.

“software reliability” means the probability that software will notcause the failure of a system for a specified time under specifiedconditions.

“software review” means an evaluation of software elements to ascertaindiscrepancies from planned results and to recommend improvement.

“software safety change analysis” means analysis of the safety-criticaldesign elements affected directly or indirectly by the change to showthe change does not create a new hazard, does not impact on a previouslyresolved hazard, does not make a currently existing hazard more severe,and does not adversely affect any safety-critical software designelement.

“software safety code analysis” means verification that thesafety-critical portions of the design are correctly implemented in thecode.

“software safety design analysis” means verification that thesafety-critical portion of the software design correctly implements thesafety-critical requirements and introduces no new hazards.

“software safety requirements analysis” means analysis evaluatingsoftware and interface requirements to identify errors and deficienciesthat could contribute to a hazard.

“software safety test analysis” means analysis demonstrating that safetyrequirements have been correctly implemented and that the softwarefunctions safely within its specified environment.

“system administrator” means the person that is charged with the overalladministration, and operation of a computer system. The SystemAdministrator is normally an employee or a member of the establishment.

“system analysis” means a systematic investigation of a real or plannedsystem to determine the functions of the system and how they relate toeach other and to any other system.

“system design” means a process of defining the hardware and softwarearchitecture, components, modules, interfaces, and data for a system tosatisfy specified requirements.

“top-down design” means pertaining to design methodology that startswith the highest level of abstraction and proceeds through progressivelylower levels.

“traceability analysis” means the tracing of Software RequirementsSpecifications requirements to system requirements in conceptdocumentation.

“validation” means establishing documented evidence which provides ahigh degree of assurance that a specific process will consistentlyproduce a product meeting its predetermined specifications and qualityattributes.

“validation, process” means establishing documented evidence whichprovides a high degree of assurance that a specific process willconsistently produce a product meeting its predetermined specificationsand quality characteristics.

“validation, prospective” means validation conducted prior to thedistribution of either a new product, or product made under a revisedmanufacturing process, where the revisions may affect the product'scharacteristics.

“validation protocol” means a written plan stating how validation willbe conducted, including test parameters, product characteristics,production equipment, and decision points on what constitutes acceptabletest results.

“validation, retrospective” means validation of a process for a productalready in distribution based upon accumulated production, testing andcontrol data. Retrospective validation can also be useful to augmentinitial premarket prospective validation for new products or changedprocesses. Test data is useful only if the methods and results areadequately specific. Whenever test data are used to demonstrateconformance to specifications, it is important that the test methodologybe qualified to assure that the test results are objective and accurate.

“validation, software” means. determination of the correctness of thefinal program or software produced from a development project withrespect to the user needs and requirements. Validation is usuallyaccomplished by verifying each stage of the software development lifecycle.

“structured query language” means a language used to interrogate andprocess data in a relational database. Originally developed for IBMmainframes, there have been many implementations created for mini andmicro computer database applications. SQL commands can be used tointeractively work with a data base or can be embedded with aprogramming language to interface with a database.

“Batch” means a specific quantity of a drug or other material that isintended to have uniform character and quality, within specified limits,and is produced according to a single manufacturing order during thesame cycle of manufacture.

“Component” means any ingredient intended for use in the manufacture ofa drug product, including those that may not appear in such drugproduct.

“Drug product” means a finished dosage form, for example, tablet,capsule, solution, etc., that contains an active drug ingredientgenerally, but not necessarily, in association with inactiveingredients. The term also includes a finished dosage form that does notcontain an active ingredient but is intended to be used as a placebo.

“Active ingredient” means any component that is intended to furnishpharmacological activity or other direct effect in the diagnosis, cure,mitigation, treatment, or prevention of disease, or to affect thestructure or any function of the body of man or other animals. The termincludes those components that may undergo chemical change in themanufacture of the drug product and be present in the drug product in amodified form intended to furnish the specified activity or effect.

“Inactive ingredient” means any component other than an activeingredient.

“In-process material” means any material fabricated, compounded,blended, or derived by chemical reaction that is produced for, and usedin, the preparation of the drug product.

“Lot number, control number, or batch number” means any distinctivecombination of letters, numbers, or symbols, or any combination thereof,from which the complete history of the manufacture, processing, packing,holding, and distribution of a batch or lot of drug product or othermaterial can be determined.

“Quality control unit” means any person or organizational elementdesignated by the firm to be responsible for the duties relating toquality control.

“Acceptance criteria” means the product specifications andacceptance/rejection criteria, such as acceptable quality level andunacceptable quality level, with an associated sampling plan, that arenecessary for making a decision to accept or reject a lot or batch.

“Manufacturing execution system” (a.k.a. MES) means an integratedhardware and software solution designed to measure and controlactivities in the production areas of manufacturing organizations toincrease productivity and improve quality.

“Process analytical technology” (a.k.a. PAT) means a mechanism todesign, analyze, and control pharmaceutical manufacturing processesthrough the measurement of critical process parameters and qualityattributes.

“New molecular entity” (a.k.a. NME or New Chemical Entity (“CNE”)) meansa drug that contains no active moiety that has been approved by FDA. Anactive moiety means the molecule or ion, excluding those appendedportions of the molecule that cause the drug to be an ester, salt(including a salt with hydrogen or coordination bonds), or othernoncovalent derivative (such as a complex, chelate, or clathrate) of themolecule, responsible for the physiological or pharmacological action ofthe drug substance.

“Crystallization process” means the natural or artificial process offormation of solid crystals from a homogeneous solution consisting oftwo (2) major steps, (i) nucleazation and (ii) crystal growth.

“Tablet press” means the apparatus or machine which compresses powderinto a tablet by the action of one upper and one lower punch slidingalong closing cam tracks and meeting together at a predetermined pointin a die between the two main pressure rolls.

“Chromatography” means collectively a family of laboratory techniquesfor the separation of mixtures. It involves passing a mixture whichcontains the analyte through a stationary phase, which separates it fromother molecules in the mixture and allows it to be isolated.

“pH” means is a measure of the activity of hydrogen ions (H⁺) in asolution and, therefore, its acidity.

II.) NANOMATERIAL

The present invention provides for nanomaterials which are manufacturedto achieve a desired function or property that will assist in themanufacturing of drugs. Nanomaterials of the inventions comprisenanostructures, nanocrystals, nanowires, nanotubes, nanofillers,nanocomposites, and precursors or any combination thereof. Thenanomaterials useful in the present invention can also further compriseligands conjugated, cooperated, associated or attached to their surfaceas described throughout. Suitable ligands include any group known tothose skilled in the art. Use of such ligands can enhance the ability ofthe nanocrystals to incorporate into various solvents and matrixes,including polymers. Increasing the miscibility (i.e., the ability to bemixed without separation) of the nanocrystals in various solvents andmatrixes allows them to be distributed throughout a polymericcomposition such that the nanocrystals do not aggregate together andtherefore do not scatter light. Such ligands are described as“miscibility-enhancing” ligands herein.

In a further embodiment, the invention provides polymeric layerscomprising a polymer and nanocrystals embedded within the polymer, suchthat the layers act as photon-filtering nanocomposites. Suitably, thenanocrystals will be prepared from semiconductor materials, but anysuitable material described throughout can be used to prepare thenanocrystals. In certain embodiments, the nanocrystals will have a sizeand a composition such that the nanocrystals absorb light of aparticular wavelength or over a range of wavelengths. As such, thenanocrystals utilized in these embodiments are tailored such that theirabsorption characteristics are enhanced or maximized, while theiremission characteristics are minimized, i.e. they will absorb light in ahighly efficient manner, but suitably will emit only a very low level,or preferably no light. In other embodiments, however, thephoton-filtering nanocomposites can also comprise nanocrystals that havehigh emission properties and emit light at a particular wavelength asdiscussed throughout. As such, the present invention providesnanocomposites that comprise different types of nanocrystals such thatthe nanocomposites exhibit several, or all, of the properties discussedthroughout, in a layer. In embodiments of the present invention wherethe photon-filtering polymeric layers are used to coat optical devices,such optical devices can be refractive (e.g., lenses) or reflective(e.g., mirrors).

Additionally, in certain embodiments of the present invention where thephoton-filtering polymeric layers are used to encapsulate activedevices, such active devices can be any device known to the skilledartisan. As used herein an “active device” is one that requires a sourceof energy for its operation and has an output that is a function ofpresent and past input signals. Examples of active devices include, butare not limited to, controlled power supplies, transistors, diodes,including light emitting diodes (LEDs), light detectors, amplifiers,transmitters and other semiconductor devices in basic input/outputsystems (“I/O”).

By controlling the size and composition of the nanocrystals used in thepractice of the present invention, the nanocrystals will absorb light ofa particular wavelength, or a particular range of wavelengths, while notscattering light. The ability to make nanocrystals out of differentsemiconductors, and control their size, allows for polymeric layers tobe fabricated with nanocrystals that will absorb light from the UV, tovisible, to near infrared (NIR), to infrared (IR) wavelengths.Nanocrystals for use in the present invention will suitably be less thanabout 100 nm in size, and down to less than about 2 nm in size. Insuitable embodiments, the nanocrystals of the present invention absorbvisible light. As used herein, visible light is electromagneticradiation with wavelengths between about 380 and about 780 nanometersthat is visible to the human eye. Visible light can be separated intothe various colors of the spectrum, such as red, orange, yellow, green,blue, indigo and violet. The photon-filtering nanocomposites of thepresent invention can be constructed so as to absorb light that makes upany one or more of these colors. For example, the nanocomposites of thepresent invention can be constructed so as to absorb blue light, redlight, or green light, combinations of such colors, or any colors inbetween. As used herein, blue light comprises light between about 435 nmand about 500 nm, green light comprises light between about 520 nm and565 nm and red light comprises light between about 625 nm and about 740nm in wavelength. One of ordinary skill will be able to constructnanocomposites that can filter any combination of these wavelengths, orwavelengths between these colors, and such nanocomposites are embodiedby the present invention.

As disclosed herein, the nanocrystals useful in the practice of thepresent invention can have a composition and a size such that theyabsorb light at a particular wavelength(s) and emit at a particularwavelength(s). In certain embodiments, the polymeric layers of thepresent invention can comprise combinations of nanocrystals thatfunction in the various ways described herein. For example, ananocomposite of the present invention can comprise nanocrystals havingspecific, enhanced emission properties, others having specific, enhancedabsorption properties but low emission properties, and the entirenanocomposite can be constructed such that the layer has a specificrefractive index that is matched or tailored for a specific purpose.Combined in such a way, the polymeric layers of the present inventioncan be used as encapsulates for active devices (e.g., LEDs) that emitlight of a certain wavelength, filter out other wavelengths and have arefractive index appropriately matched to an active device and/or anadditional substrate or coating.

In preferred embodiments, it is desirable that the nanocrystals do notaggregate. That is, that they remain separate from each other in thepolymeric layer and do not coalesce with one another to form largeraggregates. This is important, as individual crystals will not scatterlight passing through the layer, while larger aggregated structures cancreate an opaque layer that can hinder the passage of light. However,depending on the parameters of the pharmaceutical manufacturing processin which the nanomaterials are used the degree of aggregation may needto be modified to achieve the desired result.

Dispersion of nanocrystals in a host matrix can be controlled byminimizing phase separation and aggregation that can occur when mixingthe nanocrystals into the matrixes. A basic strategies known in the artis to design a 3-part ligand, in which the head-group, tail-group andmiddle/body-group can each be independently fabricated and optimized fortheir particular function, and then combined into an ideally functioningcomplete surface ligand. In on embodiment, the head group is selected tobind specifically to the semiconductor material of the nanocrystal. Inone embodiment, the tail group is designed to interact strongly with thematrix material and be miscible in the solvent utilized (and can,optionally, contain a linker group to the host matrix) to allow maximummiscibility and loading density in the host matrix without nanocrystalaggregation. In one embodiment, the middle or body group is selected forspecific electronic functionality (e.g., charge isolation, Input/output,detector, etc).

In another aspect of the invention nanomaterials comprise nanowires.While the example implementations described herein principally use Si,other types of nanowires (and other nanostructures such as nanoribbons,nanotubes, nanorods and the like) can be used including semiconductivenanowires, that are comprised of semiconductor material selected from,e.g., Si, Ge, Sn, Se, Te, B, C (including diamond), P, B—C, B—P(BP6),B—Si, Si—C, Si—Ge, Si—Sn and Ge—Sn, SiC, BN/BP/BAs, AlN/AlP/AlAs/AlSb,GaN/GaP/GaAs/GaSb, InN/InP/InAs/InSb, BN/BP/BAs, AlN/AlP/AlAs/AlSb,GaN/GaP/GaAs/GaSb, InN/InP/InAs/InSb, ZnO/ZnS/ZnSe/ZnTe, CdS/CdSe/CdTe,HgS/HgSe/HgTe, BeS/BeSe/BeTe/MgS/MgSe, GeS, GeSe, GeTe, SnS, SnSe, SnTe,PbO, PbS, PbSe, PbTe, CuF, CuCl, CuBr, CuI, AgF, AgCl, AgBr, Agl,BeSiN2, CaCN2, ZnGeP2, CdSnAs2, ZnSnSb2, CuGeP3, CuSi2P3, (Cu, Ag)(Al,Ga, In, TI, Fe)(S, Se, Te)2, Si3N4, Ge3N4, Al.sub.2O.sub.3, (Al, Ga, In)2 (S, Se, Te)3, Al2CO, and an appropriate combination of two or moresuch semiconductors.

Additionally, the nanowires of the invention can include carbonnanotubes, or conductive or semiconductive organic polymer materials,(e.g., pentacene, and transition metal oxides).

In another aspect of the invention, nanomaterials of the inventioncomprise nanotubes. Nanotubes can be formed in combinations/thin filmsof nanotubes as is described herein for nanowires, alone or incombination with nanowires, to provide the properties and advantagesdescribed herein.

a. Functional Properties of Nanomaterials

In one aspect of the invention nanomaterials are used in thepharmaceutical manufacturing process. In one embodiment, thenanomaterial is designed to include a functional property. The preferredfunctional property is one that provides a synergy with thepharmaceutical manufacturing process that the nanomaterial is beingutilized. For example, nanomaterials may possess optical propertiesuseful in detection of particulates or contaminates in gas or aerosols.In another example, a nanomaterial may possess thermal propertieswhereby deviations in temperature may be detected.

A very wide variety of pure phase materials such as polymers are nowreadily known in the art. However, low cost pure phase materials aresomewhat limited in the achievable ranges of a number of properties,including, for example, electrical conductivity, magnetic permeability,dielectric constant, and thermal conductivity. In order to circumventthese limitations, it has become common to form composites, in which amatrix is blended with a filler material with desirable properties.

In one embodiment, the invention comprises a nanofiller, intimatelymixed with a matrix to form a nanostructured composite. At least one ofthe nanostructured filler and the nanostructured composite has a desiredmaterial property which differs by at least 20% from the same materialproperty for a micron-scale filler or a micron-scale composite,respectively. The desired material property is selected from the groupconsisting of refractive index, transparency to light, reflectioncharacteristics, resistivity, permittivity, permeability, coercivity,B-H product, magnetic hysteresis, breakdown voltage, skin depth, curietemperature, dissipation factor, work function, band gap,electromagnetic shielding effectiveness, radiation hardness, chemicalreactivity, thermal conductivity, temperature coefficient of anelectrical property, voltage coefficient of an electrical property,thermal shock resistance, biocompatibility and wear rate.

The nanofiller may comprise one or more elements selected from the s, p,d, and f groups of the periodic table, or it may comprise a compound ofone or more such elements with one or more suitable anions, such asaluminum, antimony, boron, bromine, carbon, chlorine, fluorine,germanium, hydrogen, indium, iodine, nickel, nitrogen, oxygen,phosphorus, selenium, silicon, sulfur, or tellurium. The matrix may be apolymer (e.g., poly(methyl methacrylate), poly(vinyl alcohol),polycarbonate, polyalkene, or polyaryl), a ceramic (e.g., zinc oxide,indium-tin oxide, hafnium carbide, or ferrite), or a metal (e.g.,copper, tin, zinc, or iron). Loadings of the nanofiller may be as highas 95%, although loadings of 80% or less are preferred. The inventionalso comprises devices which incorporate the nanofiller (e.g.,electrical, magnetic, optical, biomedical, and electrochemical devices).

(i) Nanomaterial with Thermal Conductivity

In one aspect of the invention, the nanomaterial possesses thefunctional property of thermal conductivity. Any nanoparticle that canbe functionalized and which has a higher thermal conductivity than theorganic matrix can be used to prepare the present compositions. Suitablenanoparticles include but are not limited to colloidal silica,polyhedral oligomeric silsequioxane (“POSS”), nano-sized metal oxides(e.g. alumina, titania, zirconia), nano-sized metal nitrides (e.g. boronnitrides, aluminum nitrides) and nano-metal particles (e.g., silver,gold, or copper nanoparticles). In particularly useful embodiments, thenanoparticles are organo-functionalized POSS materials or colloidalsilica. Colloidal silica exists as a dispersion of submicron-sizedsilica (SiO₂) particles in an aqueous or other solvent medium. Thecolloidal silica contains up to about 85 weight % of silicon dioxide(SiO₂) and typically up to about 80 weight % of silicon dioxide. Theparticle size of the colloidal silica is typically in a range betweenabout 1 nanometers) (“nm” and about 250 nm, and more typically in arange between about 5 nm and about 150 nm. The fillers used aremicron-sized thermally conductive materials and can be reinforcing ornon-reinforcing. In one embodiment, the present nanomaterial withthermal functionality can be formed into sheets and cut into any desiredshape. In a preferred embodiment, the nanomaterials can advantageouslybe used for thermal interface pads and positioned on thermal biosensors.

(ii) Nanomaterial with Porosity/Permeability

In one embodiment, nanomaterials possess predefined porosity andpermeability properties. The properties are useful in the design offilters that are used in the pharmaceutical manufacturing process. Thefilers can be used for such process as purification, etc. Thenanomaterials are designed with a membrane or layer is designed to blockcertain objects or substances while letting others through. Theporosity/permeability properties of the nanomaterials can be used toseparate liquids from liquids, solids from liquids, gas from liquids, orany combination of thereof. In a preferred embodiment, theporosity/permeability properties are designed to be advantageous to themanufacturing of pharmaceuticals.

(iii) Nanomaterial with Enhanced luminescence

In one embodiment, nanomaterials possess enhanced luminescentproperties. The nanomaterials are made from nanopowders using standardmethods known in the art. For example, luminescent nanomaterial isprepared using the following steps: forming a homogenized precursorsolution of at least one lanthanide group metal precursor and at leastone lanthanide series dopant precursor; adding a phosphate source and afuel to the precursor solution; removing water from the precursorsolution to leave a reaction concentrate; and igniting the reactionconcentrate to form a powder comprising the plurality of nanoparticles.The nanomaterials of the invention can be used in pharmaceuticalmanufacturing applications such as, display devices, fluorescent lamps,compact fluorescent lamps, linear fluorescent lamps, light emittingdiodes, and imaging applications. In a preferred embodiment, thenanomaterials will be used in the quality control imaging ofpharmaceuticals.

(iv) Nanomaterial with Enhanced Acoustics

In one embodiment, nanomaterials possess enhanced acoustic functions.The nanomaterials are made from using standard methods known in the art.For example, a surface acoustic wave device fabricated on a lithiumniobate substrate and a sensing bilayer positioned on the acoustic pathof the surface acoustic wave device, the sensing bilayer furthercomprising nanocrystalline or other nanomaterial such as nanoparticlesor nanowires of palladium and metal free phthalocyanine. Preferably, thesurface acoustic wave device has a center frequency of about 200 MHz.Nanomaterials with enhanced acoustic properties will respond to gases(i.e. hydrogen, helium, etc.) in near real time, at low (room)temperature, without being affected by CO₂, CH₄ and other gases, in airambient or controlled ambient, providing sensitivity to low ppm levels.In a preferred embodiment, the nanomaterials will detect gases used inthe manufacturing of pharmaceuticals.

(v) Nanomaterial with Enhanced Magnetic Properties

In one embodiment, nanomaterials possess enhanced magnetic functions.The nanomaterials are made from using standards known in the art. Forexample, a solvent, preferably an ether or an aromatic solvent such astoluene, anisole, dioctylether, or the like, is added to a carboxylicacid, preferably Oleic acid, or the like. An amine, preferablyOleylamine or the like is then added to the solvent and Oleic acidsolution to complete solution A. It will be appreciated that othersolvents or amines not listed here may be used to perform the samedecomposition. The solution A is added to a metal-organic precursor toform solution B. Solution B is then heated, for example by radiation atapproximately 150 degrees C. in anisole for approximately 48 hours,under pressure, for example 3 Bars of H2. Nanorods begin to appear. Thenanorods are crystalline hexagonal close packed (hcp), and grow alongthe c axis of the structure. The nanorods are in a thermodynamicallystable form of cobalt after completion of the reaction. Thesethermodynamically stable cobalt nanorods will not rearrange into otherforms such as spherical nanoparticles or any other form.

The nanoparticles that result from this embodiment exhibit magneticproperties, such as for example: i) saturation magnetization similar tothe magnetic characteristics and properties of bulk cobalt; ii) enhancedmagnetic anisotropy and strongly enhanced coercive magnetic field (ascompared to bulk cobalt and spherical nanoparticles) due to the shapeanisotropy. The nanomaterials with enhanced magnetic properties willallow particle orientation in magnetic fields to optimize high-frequencydevice applications. In a preferred embodiment, the high-frequencydevice will be used in the pharmaceutical manufacturing process.

(vi) Nanomaterial with Enhanced Solubility

In one embodiment, nanomaterials possess enhanced solubility properties.The nanomaterials are made from using standards known in the art. Forexample, a rigid poly(aryleneethynylene)polymer is coupled with apara-diethynyl-(R₁-R_(x))arylene and an (R₁-R_(y))-para-dih-aloarylenein the presence of a first polymerization-terminating haloaryl agentunder conditions and for a period of time to produce fluorescence. Thenterminating the coupling by addition of a secondpolymerization-terminating haloaryl agent, the second haloaryl agenthaving equal or greater activity for coupling as compared to the(R₁-R_(y))-para-dihaloarylene. The nanomaterials with enhancedsolubility will provide for functional nanomaterials that can be usedfor epoxy and engineering plastic composites, filters, actuators,adhesive composites, elastomer composites, materials for thermalmanagement (interface materials, materials for heat transferapplications), improved dimensionally stable structures forsensorsoptoelectronic or microelectromechanical components orsubsystems, rapid prototyping materials, composite fibers, etc. In apreferred embodiment, the nanomaterial will be used in thepharmaceutical manufacturing process.

(vii) Shape Engineered Nanomaterials

In one embodiment, nanomaterials are engineered for specific shapes ormechanical properties. The nanomaterials are made from using standardsknown in the art. For example, nanomaterials are made with modifieddegree of agglomeration. Additionally, nanomaterials are made with amodified surface area. Additionally, nanomaterials are made withpost-processing to modify the phase and shape. Additionally,post-processing is utilized to achieve consolidation. Nanomaterials thatare shape engineered are used for ceramic, metal, or composite seals.Additionally as filters with a defined porosity gradient, monitors,sensors, drug delivery devices, and biocatalysts from nanoscale powdersusing the multi-layer laminating process to produce three-dimensionalshapes. In a preferred embodiment, the nanomaterials will be used inpharmaceutical manufacturing.

(viii) Nanomaterials Will Enhanced Optical Properties

In one embodiment, nanomaterials are engineered with enhanced opticalproperties. The nanomaterials are made from using standards known in theart. Generally, in optical lenses, the optical path length varies withdistance from its center, where optical path length is defined as theproduct of the physical path length, thickness, and the refractiveindex, n, of the lens material. In the most common lenses, therefractive index, n, is fixed and the thickness, varies. However, a lenscan also be created by keeping the thickness, constant and varying therefractive index as a function of distance from the axis of the lens.Such a lens is called a Graded Index lens, or sometimes abbreviated as aGRIN lens. The methods of the present invention can also be used tocreate GRIN lenses. Polymer/nanocrystal blends can be used to make GRINlenses due to the dramatic refractive index difference betweennanocrystals (e.g., ZnS about 2.35) and optical plastics such aspoly(methyl methacrylate) (PMMA) (refractive index about 1.45). Withnormal glass, a difference of about 0.05 refractive index units isachievable over about 8 mm. Utilizing the methods and processes of thepresent application, a difference of about 0.20 refractive index unitsover about 8 mm can be achieved to make much more powerful lenses.Nanomaterials with enhanced optical properties can be used for contactsensors, remote sensors, LIDAR, optical parametric oscillators, opticaldata storage, optical spectroscopy, optical amplifiers, wavelengthtranslation devices, super sensitive optical detection, and opticalswitches. In a preferred embodiment, the sensors with enhanced opticalproperties are used to monitor and manufacture pharmaceuticals.

III.) SENSORS

In one embodiment, the invention relates to sensors that are used in themonitoring and manufacturing of pharmaceuticals. In a preferredembodiment, the sensors are made from nanomaterials disclosed herein andare developed on a microscopic scale using MEMS(micro-electrical-mechanical-systems) technology. In one embodiment, thesensor is made from 1^(st) generation MEMS technology (i.e. a sensorelement mostly based on a silicon or similar structure, sometimescombined with analog amplification on a nanomaterial). In oneembodiment, the sensor is made from 2^(nd) generation MEMS technology(i.e. a sensor element combined with analog amplification andanalog-to-digital converter on one nanomaterial). In a preferredembodiment, the sensor is made from 3^(rd) generation MEMS technology(i.e. fusion of the sensor element with analog amplification,analog-to-digital converter and digital intelligence for linearizationand temperature compensation on the same nanomaterial). In anotherpreferred embodiment, the sensor is made from 4^(th) generation MEMStechnology (i.e. memory cells for calibration and temperaturecompensation data are added to the elements of the 3rd generationsensor). The advantages of using sensors made out of nanomaterials isthe sensors can reach significantly higher speeds and sensitivity thatmacroscale sensors.

It will be appreciated by one of skill in the art that the type ofsensor needed will be a direct function to the pharmaceuticalmanufacturing process that is being monitored and for what purpose. Forexample, monitoring the levels of contaminate in an active ingredientwill require different monitoring parameters that monitoring thetemperature of pH of a final product. In these situations, it will beappreciated by one of ordinary skill that either (i) the same sensorscan be used with different detecting criteria or (ii) different types ofsensors can be used to achieve the best level of monitoring.

Accordingly, sensors of the present invention comprise thermal,electromagnetic, mechanical, chemical, optical, radiation, acoustic, andbiological sensors. In one embodiment, thermal sensors include but arenot limited to thermometers, thermocouples, temperature sensitiveresistors, bolometers, calorimeter.

In a further embodiment, electromagnetic sensors include but are notlimited to ohmmeters, multimeters, galvanometers, ammeters, leafelectroscopes, watt-hour meters, magnetic compasses, fluxgate compasses,magnetometers, and metal detectors.

In a further embodiment, mechanical sensors include but are not limitedto barometers, barographs, pressure gauges, air speed indicators, rateof change sensors, flow sensors, anemometers, flow meters, gas meters,water meters, mass flow sensors, acceleration sensors, whisker sensors,Quadrature wheels, and positions switches.

In a further embodiment, chemical sensors include but are not limited tooxygen sensors (a.k.a. λ sensors), ion-selective electrodes, pH glasselectrodes, and redox electrodes.

In a further embodiment, optical and radiation sensors include but arenot limited to RADAR, LIDAR, dosimeters, particle detectors,scintillators, wire chambers, cloud chambers, bubble chambers, infraredsensors, photocells, photodiodes, phototransistors, image sensors;vacuum tube devices, and proximity sensors.

In a further embodiment, acoustic sensors include but are not limited toultrasounds and SONAR.

In a further embodiment, biological sensors include but are not limitedto biosensors that can detect physical aspects of the externalenvironment such as light, motion, temperature, magnetic fields,gravity, humidity, vibration, pressure, electrical fields, and sound.Additionally, biosensors that can detect environmental molecules such astoxins, nutrients, and pheromones are within the scope of the invention.Additionally, biosensors that can detect metabolic parameters such asglucose level and oxygen level are within the scope of the invention.

In another aspect, this invention also includes a method of producing animproved sensor device. A non-stoichiometric nanopowder is sonicated ina solvent to form a slurry. The slurry is brushed onto screen-printedelectrodes and allowed to dry at to remove the solvent. A dissolvedpolymer may also be included in the slurry. The screen-printedelectrodes may be gold electrodes on an alumina substrate. The screenmay be made from stainless steel mesh at least 8.times.10 inches insize, with a mesh count of 400, a wire diameter of 0.0007 inches, a biasof 45.degree., and a polymeric emulsion of 0.0002 inches.

In another aspect, this invention includes an improved sensor deviceprepared from a screen printable paste. A nanopowder and polymer aremechanically mixed; a screen-printing vehicle is added to the mixtureand further mechanically mixed. The mixture is milled and screen-printedonto prepared electrodes. The paste is allowed to level and dry. Thisinvention also includes the improved sensor devices produced by theabove processes.

In another aspect of the invention, thermal sensors are prepared fromnanostructured powders. These thermal sensors can be used to monitoraspects of the pharmaceutical manufacturing process including but notlimited to monitor radiation, power, heat and mass flow, charge andmomentum flow, and phase transformation.

IV.) SOFTWARE PROGRAM AND COMPUTER PRODUCT

The invention provides for a software program that is programmed in ahigh-level or low-level programming language, preferably a relationallanguage such as structured query language which allows the program tointerface with an already existing program or a database. Otherprogramming languages include but are not limited to C, C++, FORTRAN,Java, Perl, Python, Smalltalk and MS visual basic. Preferably, however,the program will be initiated in parallel with the manufacturing processor quality assurance (“QA”) protocol. This will allow the ability tomonitor the manufacturing and QA process from its inception. However, insome instances the program can be bootstrapped into an already existingprogram that will allow monitoring from the time of execution (i.e.bootstrapped to configurable off-the-shelf software).

It will be readily apparent to one of skill in the art that thepreferred embodiment will be a software program that can be easilymodified to conform to numerous software-engineering environments. Oneof ordinary skill in the art will understand and will be enabled toutilize the advantages of the invention by designing the system withtop-down design. The level of abstraction necessary to achieve thedesired result will be a direct function of the level of complexity ofthe process that is being monitored. For example, the critical controlpoint for monitoring an active ingredient versus an inactive ingredientmay not be equivalent. Similarly, the critical control point formonitoring an in-process material may vary from component to componentand often from batch to batch.

One of ordinary skill will appreciate that to maximize results theability to amend the algorithm needed to conform to the validation andQA standards set forth by the quality control unit on each step duringmanufacture will be preferred. This differential approach to programmingwill provide the greatest level of data analysis leading to the higheststandard of data integrity.

The preferred embodiments may be implemented as a method, system, orprogram using standard software programming and/or engineeringtechniques to produce software, firmware, hardware, or any combinationthereof. The term “computer product” as used herein is intended toencompass one or more computer programs and data files accessible fromone or more computer-readable devices, firmware, programmable logic,memory devices (e.g. EEPROM's, ROM's, PROM's, RAM's, SRAM's, etc.)hardware, electronic devices, a readable storage diskette, CD-ROM, afile server providing access to programs via a network transmissionline, wireless transmission media, signals propagating through space,radio waves, infrared signals, etc.

In one embodiment, the invention provides for methods of interfacing asoftware program with a nanomaterial of the invention whereby thenanomaterial is integrated into the pharmaceutical manufacturing processand control of the pharmaceutical manufacturing process is attained. Theintegration can be used for routine monitoring, quality control,maintenance, hazard mitigation, validation, etc.

In one embodiment, the interface is a combinational logic circuit havingand I/O and power supply. In a further embodiment, the interfacecomprises a chemically assembled electronic nanomaterial having an I/Owhereby the nanomaterial is programmed with a logic function. In afurther embodiment, the interface comprises a chemically assembledelectronic nanomaterial having an I/O whereby the nanomaterial isprogrammed with a logic function and whereby the nanomaterial isconnected to a further nanomaterial via a electronically conductivenanowire whereby the further nanomaterial is programmed with a logicfunction. One of skill in the art will understand and be enabled toachieve a bottom-up approach to designing the chemically assemblednanomaterial whereby each nanomaterial is linked via nanowires andwhereby the top design is the end user (i.e. human) most preferably amember of the pharmaceutical manufacturing quality control unit. One ofskill in the art will also appreciate a top-down design to softwareprogramming. It is the purpose of the present invention to provide ahybrid approach (i.e. bottom-up and top-down design) to interfacingnanomaterials and software programs that are useful for monitoring andexecuting the pharmaceutical manufacturing process. (See, FIG. 1).

In one embodiment the nanomaterials are aligned in a linear fashion tocreate an integrated circuit by forming an array of nanowires on asubstrate (nanolayer). In a further embodiment, the nanowires are formedin a two dimensional grid like structure. In one embodiment, thenanomaterials that are interfaced include an input/output (I/O)isolation for power and clock management.

Those of skill in the art will recognize that many modifications may bemade without departing from the scope of the present invention.

V.) ANALYSIS

The invention provides for a method of analyzing data that is compiledas a result of the manufacturing of pharmaceuticals. Further theinvention provides for the analysis of data that is compiled as a resultof a QA program used to monitor the manufacture of drugs in order tomaintain the highest level of data integrity. In one embodiment, theparameters of the data will be defined by the quality control unit.Generally, the quality control unit will provide endpoints that need tobe achieved to conform to cGMP regulations or in some instances aninternal endpoint that is more restrictive to the minimum levels thatneed to be achieved.

In a preferred embodiment, the invention provides for data analysisusing boundary value analysis. The boundary value will be set forth bythe quality control unit. Using the boundary values set forth for aparticular phase of manufacture the algorithm is defined. Once thealgorithm is defined, an algorithm analysis (i.e. logic analysis) takesplace. One of skill in the art will appreciate that a wide variety oftools are used to confirm algorithm analysis such as an accuracy studyprocessor.

One of ordinary skill will appreciate that different types of data willrequire different types of analysis. In a further embodiment, theprogram provides a method of analyzing block data via a block check. Ifthe block check renders an affirmative analysis, the benchmark has beenmet and the analysis continues to the next component. If the block checkrenders a negative the data is flagged via standard recognition filesknown in the art and a hazard analysis and hazard mitigation occurs.

In a further embodiment, the invention provides for data analysis usingbranch analysis. The test cases will be set forth by the quality controlunit.

In a further embodiment, the invention provides for data analysis usingcontrol flow analysis. The control flow analysis will calibrate thedesign level set forth by the quality control unit which is generated inthe design phase.

In a further embodiment, the invention provides for data analysis usingfailure analysis. The failure analysis is initiated using the failurebenchmark set forth by the quality control unit and then using standardtechniques to come to error detection. The preferred technique will betop-down. For example, error guessing based on quality control groupparameters which are confirmed by error seeding.

In a further embodiment, the invention provides for data analysis usingpath analysis. The path analysis will be initiated after the designphase and will be used to confirm the design level. On of ordinary skillin the art will appreciate that the path analysis will be a dynamicanalysis depending on the complexity of the program modification. Forexample, the path analysis on the output of an end product will beinherently more complex that the path analysis for the validation of anin-process material. However, one of ordinary skill will understand thatthe analysis is the same, but the parameters set forth by the qualitycontrol unit will differ.

The invention provides for a top-down design to software analysis. Thispreferred embodiment is advantageous because the parameters of analysiswill be fixed for any given process and will be set forth by the qualitycontrol unit. Thus, performing software safety code analysis thensoftware safety design analysis, then software safety requirementsanalysis, and then software safety test analysis will be preferred.

The aforementioned analysis methods are used for several non-limitingembodiments, including but not limited to, validating QA software,validating pharmaceutical manufacturing, and validating process designswherein the integration of the system design will allow for moreefficient determination of acceptance criteria in a batch, in-processmaterial, batch number, control number, and lot number and allow forincreased access time thus achieving a more efficient cost-savingmanufacturing process.

VI. MANUFACTURING EXECUTION SYSTEMS (MES)

In one embodiment, the interfaced nanomaterial is integrated into amanufacturing execution system that controls the pharmaceuticalmanufacturing process. It will be understood by one of skill in the artthat the computer product integrates the hardware via generallyunderstood devices in the art (i.e. attached to the analog device via ananalog to digital converter).

The nanomaterial is integrated into the manufacturing execution systemon a device-by-device basis. As previously set forth, the acceptancecriteria of all devices used in the drug product manufacture for thepurposes of the manufacturing execution system are determined by thequality control unit. The analysis of the pharmaceutical manufacturingoccurs using any of the methods disclosed herein. (See FIG. 2). Theprogram monitors and processes the data and stores the data usingstandard methods. The data is provided to an end user or a plurality ofend users for assessing the quality of data generated by the device ordevices. Furthermore, the data is stored for comparative analysis toprevious batches to provide a risk-based assessment in case of failure.Using the historical analysis will provide a more streamlinedpharmaceutical manufacturing process and will monitor to ensure thatproduct quality is maximized. In addition, the invention comprisesmonitoring the data from initial process, monitoring the data at the endprocess, and monitoring the data from a routine maintenance schedule toensure the system maintain data integrity and validation standardspredetermined by the quality control unit.

VII.) KITS/ARTICLES OF MANUFACTURE

For use in basic input/output systems, hardware calibrations, softwarecalibrations, computer systems audits, computer system securitycertification, data validation, different software system analysis,quality control, and the manufacturing of drug products describedherein, kits are within the scope of the invention. Such kits cancomprise a carrier, package, or container that is compartmentalized toreceive one or more containers such as boxes, shrink wrap, and the like,each of the container(s) comprising one of the separate elements to beused in the method, along with a program or insert comprisinginstructions for use, such as a use described herein.

The kit of the invention will typically comprise the container describedabove and one or more other containers associated therewith thatcomprise materials desirable from a commercial and user standpoint,programs listing contents and/or instructions for use, and packageinserts with instructions for use.

A program can be present on or with the container. Directions and orother information can also be included on an insert(s) or program(s)which is included with or on the kit. The program can be on orassociated with the container.

The terms “kit” and “article of manufacture” can be used as synonyms.

The article of manufacture typically comprises at least one containerand at least one program. The containers can be formed from a variety ofmaterials such as glass, metal or plastic.

EXAMPLES

Various aspects of the invention are further described and illustratedby way of the several examples that follow, none of which is intended tolimit the scope of the invention.

Example 1 Methods of Interfacing Nanomaterials with Software Program

The nanomaterial or a plurality of nanomaterials disclosed herein aredesigned via bottom-up design whereby the nanomaterial is designed witha particular functionality. It will be understood by one of skill in theart that the functionality is determined by the pharmaceuticalmanufacturing process that is being analyzed. The nanomaterial is loadedwith an electrical circuit with an I/O interface. Additionally, thesoftware program, computer readable code, and methods disclosed hereinare designed by standard methods using a top-down design approach toprogramming. The software program is interfaced with the functionalnanomaterial via the circuit.

The interfaced nanomaterial is used to execute or monitor thepharmaceutical manufacturing process. The nanomaterial is integratedinto the pharmaceutical manufacturing system on a device-by-devicebasis. As previously set forth, the acceptance criteria of all devicesused in the drug product manufacture for the purposes of themanufacturing process are determined by the quality control unit. Theanalysis of the software and hardware occurs using any of the methodsdisclosed herein. The program monitors and processes the data and storesthe data using standard methods. The data is provided to an end user ora plurality of end users for assessing the quality of data generated bythe device. Furthermore, the data is stored for comparative analysis toprevious batches to provide a risk-based assessment in case of failure.Using the historical analysis will provide a more streamlinedmanufacturing approach and will provide cost-saving over time. Inaddition, the invention comprises monitoring the data from initialprocess, monitoring the data at the end process, and monitoring the datafrom a routine maintenance schedule to ensure the system maintain dataintegrity and validation standard predetermined by the quality controlunit.

The invention further comprises implementation of the nanomaterial andsoftware program described herein into the crystallization process, thetablet press process, the chromatography process, the pH monitoringprocess, the liquid mixing process, the powder blending process, thewater-for-injection systems, the water purification systems, the cellculture systems, and the finishing and packaging systems subset(s) ofthe pharmaceutical manufacturing process whereby the data compiled bythe subset processes is tracked continuously overtime and said data isused to analyze the subset processes and whereby said data is integratedand used to analyze the quality control process of the pharmaceuticalmanufacturing process at-large. (See FIG. 2).

Example 2 Integration of Software Program into PharmaceuticalManufacturing Hardware System Utilizing Nanomaterials

The nanomaterial or a plurality of nanomaterials disclosed herein aredesigned via bottom-up design whereby the nanomaterial is designed witha particular functionality. It will be understood by one of skill in theart that the functionality is determined by the pharmaceuticalmanufacturing process that is being analyzed. The nanomaterial is loadedwith an electrical circuit with an I/O interface. Additionally, thesoftware program, computer readable code, and methods disclosed hereinare designed by standard methods using a top-down design approach toprogramming. The software program is interfaced with the functionalnanomaterial via the circuit.

The invention comprises the integration of the nanomaterial into amanufacturing hardware system. In this context, the term “hardware”means any physical device used in the pharmaceutical manufacturingprocess including, but not limited to, blenders, bio-reactors, cappingmachines, chromatography/separation systems, chilled water/circulating,glycol, coldrooms, clean steam, clean-in-place (CIP), compressed air,D.I./R.O. watersystems, dry heat sterilizers/ovens, fermentationequipment/bio reactors, freezers, filling equipment,filtration/purification, HVAC: environmental controls,incubators/environmentally controlled chambers, labelers,lyophilizers/freeze, dryers, mixing tanks, modular cleanrooms,neutralization systems, plant steam and condensate, processtanks/pressure, vessels, refrigerators, separation/purificationequipment, specialty gas, systems, steam generators/pure steam systems,steam sterilizers, stopper washers, solvent recovery systems, towerwater systems, waste inactivation systems/“kill” systems, vialinspection systems, vial washers, water for injection (WFI) systems,pure water systems, washers (glass, tank, carboys, etc.).

The interfaced nanomaterial is used to execute or monitor thepharmaceutical manufacturing process. The nanomaterial is integratedinto the pharmaceutical manufacturing system on a device-by-devicebasis. As previously set forth, the acceptance criteria of all devicesused in the drug product manufacture for the purposes of themanufacturing process are determined by the quality control unit. Theanalysis of the software and hardware occurs using any of the methodsdisclosed herein. The program monitors and processes the data and storesthe data using standard methods. The data is provided to an end user ora plurality of end users for assessing the quality of data generated bythe device. Furthermore, the data is stored for comparative analysis toprevious batches to provide a risk-based assessment in case of failure.Using the historical analysis will provide a more streamlinedmanufacturing approach and will provide cost-saving over time. Inaddition, the invention comprises monitoring the data from initialprocess, monitoring the data at the end process, and monitoring the datafrom a routine maintenance schedule to ensure the system maintain dataintegrity and validation standard predetermined by the quality controlunit.

The invention further comprises implementation of the nanomaterial andsoftware program described herein into the crystallization process, thetablet press process, the chromatography process, the pH monitoringprocess, the liquid mixing process, the powder blending process, thewater-for-injection systems, the water purification systems, the cellculture systems, and the finishing and packaging systems subset(s) ofthe pharmaceutical manufacturing process whereby the data compiled bythe subset processes is tracked continuously overtime and said data isused to analyze the subset processes and whereby said data is integratedand used to analyze the quality control process of the pharmaceuticalmanufacturing process at-large. (See FIG. 2).

Example 3 Integration of Software Program into Manufacturing SoftwareSystem Utilizing Nanomaterials

The nanomaterial or a plurality of nanomaterials disclosed herein aredesigned via bottom-up design whereby the nanomaterial is designed witha particular functionality. It will be understood by one of skill in theart that the functionality is determined by the pharmaceuticalmanufacturing process that is being analyzed. The nanomaterial is loadedwith an electrical circuit with an I/O interface. Additionally, thesoftware program, computer readable code, and methods disclosed hereinare designed by standard methods using a top-down design approach toprogramming. The software program is interfaced with the functionalnanomaterial via the circuit.

The invention comprises the integration of the computer nanomaterialinto a manufacturing software system. In this context, the term“software” means any device used in the pharmaceutical manufacturingprocess including, but not limited to user-independent audit trails,time-stamped audit trails, data security, confidentiality systems,limited authorized system access, electronic signatures, bar codes,dedicated systems, add-on systems, control files, Internet, LAN's, etc.

The interfaced nanomaterial is used to execute or monitor thepharmaceutical manufacturing process. The nanomaterial is integratedinto the pharmaceutical manufacturing system on a device-by-devicebasis. As previously set forth, the acceptance criteria of all devicesused in the drug product manufacture for the purposes of themanufacturing process are determined by the quality control unit. Theanalysis of the software and hardware occurs using any of the methodsdisclosed herein. The program monitors and processes the data and storesthe data using standard methods. The data is provided to an end user ora plurality of end users for assessing the quality of data generated bythe device. Furthermore, the data is stored for comparative analysis toprevious batches to provide a risk-based assessment in case of failure.Using the historical analysis will provide a more streamlinedmanufacturing approach and will provide cost-saving over time. Inaddition, the invention comprises monitoring the data from initialprocess, monitoring the data at the end process, and monitoring the datafrom a routine maintenance schedule to ensure the system maintain dataintegrity and validation standard predetermined by the quality controlunit.

The invention further comprises implementation of the nanomaterial andsoftware program described herein into the crystallization process, thetablet press process, the chromatography process, the pH monitoringprocess, the liquid mixing process, the powder blending process, thewater-for-injection systems, the water purification systems, the cellculture systems, and the finishing and packaging systems subset(s) ofthe pharmaceutical manufacturing process whereby the data compiled bythe subset processes is tracked continuously overtime and said data isused to analyze the subset processes and whereby said data is integratedand used to analyze the quality control process of the pharmaceuticalmanufacturing process at-large. (See FIG. 2).

Example 4 Integration of Software Program and Nanomaterials into aComprehensive Cost-Saving System

The nanomaterial or a plurality of nanomaterials disclosed herein aredesigned via bottom-up design whereby the nanomaterial is designed witha particular functionality. It will be understood by one of skill in theart that the functionality is determined by the pharmaceuticalmanufacturing process that is being analyzed. The nanomaterial is loadedwith an electrical circuit with an I/O interface. Additionally, thesoftware program, computer readable code, and methods disclosed hereinare designed by standard methods using a top-down design approach toprogramming. The software program is interfaced with the functionalnanomaterial via the circuit.

The invention comprises a program and nanomaterial or a plurality ofprograms and nanomaterials integrated into a comprehensive cost-savingpharmaceutical manufacturing system. A user, preferably a systemadministrator, logs onto the system via secure means (i.e. password orother security measures known in the art) and inputs the boundary valuesfor a particular component of the drug manufacturing process. The inputis at the initial stage, the end product state, or any predeterminedinterval in between that has been established for routine maintenance bythe quality control unit. The data is generated using any one of thevarious analysis methods described herein (as previously stated the typeof analysis used is functional to the device or protocol being monitoredor evaluated). Subsequent to the data analysis, any modifications orcorrective action to the manufacturing process is implemented. The datais then stored by standard methods known in the art. Scheduled analysisof the stored data is maintained to provide a preventative maintenanceof the manufacturing process. Over time, costs are reduced due to thetracking of data and analysis of troubled areas and frequency of hazardsthat occur on any given device in the manufacturing process. The systemis implemented on every device which plays a role in drug manufacturing.The data compiled from every device is analyzed using the methodsdescribed herein.

Example 5 Methods of Performing a Membrane Analysis

Crystallization is a key component to the pharmaceutical manufacturingprocess. Additionally, a substantial number of the pharmaceuticalsmanufactured today consist of at least one crystallization step. Despiteits significance, typical problems consist of unsuitable particle sizedistribution, impurity issues (incorrect polymorphs, etc.), inconsistentyield, etc.

In one embodiment, the nanomaterial is integrated into thecrystallization process system hardware. It will be understood by one ofskill in the art that the computer product integrates the hardware viagenerally understood devices in the art (i.e. attached to the analogdevice via an analog to digital converter, wireless means, etc.).

The nanomaterial is integrated into the crystallization system on adevice-by-device basis. As previously set forth, the acceptance criteriaof all devices used in the drug product manufacture for the purposes ofthe crystallization process are determined by the quality control unit.The nanomaterial monitors and processes the data and stores the datausing standard methods. The data is provided to an end user or aplurality of end users for assessing the quality of data generated bythe device. Furthermore, the data is stored for comparative analysis toprevious batches to provide a risk-based assessment in case of failure.Using the historical analysis will provide a more streamlinedcrystallization process and will provide cost-saving over time. Inaddition, the invention comprises monitoring the data from initialprocess, monitoring the data at the end process, and monitoring the datafrom a routine maintenance schedule to ensure the system maintain dataintegrity and validation standard predetermined by the quality controlunit.

The membrane analysis occurs on the crystallization process to determinewhen membranes are deficient for quality and yield reasons. Using theanalysis methods disclosed herein the membrane is replaced upon failuredetection. (See FIG. 3).

In one embodiment, the monitoring and analysis of the crystallizationsystems achieves a step of integration into a manufacturing executionsystem whereby manufacturing productivity and product quality areincreased. Costs are streamlined over time.

Example 6 Methods of Analyzing Surface Deviations

In tablet making, powder is actually compressed together by traditionalmeans. The end results is a pre-set tablet thickness which varies foreach particular product. An overload can occur when too much powder iscompressed at one time.

In one embodiment, the nanomaterial is integrated into the tablet presssystem hardware. It will be understood by one of skill in the art thatthe computer product integrates the hardware via generally understooddevices in the art (i.e. attached to the analog device via an analog todigital converter, wireless means, etc.).

The nanomaterial is integrated into the tablet press system on adevice-by-device basis. As previously set forth, the acceptance criteriaof all devices used in the drug product manufacture for the purposes ofthe tablet press process are determined by the quality control unit. Theprogram monitors and processes the data and stores the data usingstandard methods. The data is provided to an end user or a plurality ofend users for assessing the quality of data generated by the device.Furthermore, the data is stored for comparative analysis to previousbatches to provide a risk-based assessment in case of failure. Using thehistorical analysis will provide a more streamlined tablet press processand will monitor to ensure the tablet press set point is not overloadedor underloaded. In addition, the invention comprises monitoring the datafrom initial process, monitoring the data at the end process, andmonitoring the data from a routine maintenance schedule to ensure thesystem maintain data integrity and validation standard predetermined bythe quality control unit.

The nanomaterial analyzes tablets, etc. for surface deviation whichcould indicate contamination or similarly an out of specificationtablet, etc. (See FIG. 4).

In one embodiment, the monitoring and analysis of the tablet presssystems achieves a step of integration into a manufacturing executionsystem whereby manufacturing productivity and product quality areincreased. Costs are streamlined over time.

Example 7 Methods of Performing Tribo-Technical Analysis

The nanomaterial is integrated into a pharmaceutical manufacturingsystem to perform a tribo-technical analysis. It will be understood byone of skill in the art that the computer product integrates thehardware via generally understood devices in the art (i.e. attached tothe analog device via an analog to digital converter, wireless means,etc.).

The tribo-technical analysis provides direct three-dimensionalvisualization of surfaces, measurement of the thickness of solid andliquid lubricants at the nanoscale, measurement of frictional forces atthe nanometer scale, surface characterization of morphology, texture,and roughness, and evaluation of mechanical properties such as hardnessand elasticity, and plastic deformation at the nanometer scale. Theinvention further comprises implementation of the tribo-technicalanalysis into the crystallization process, the tablet press process, thechromatography process, the pH monitoring process, the liquid mixingprocess, the powder blending process, the water-for-injection systems,the water purification systems, the cell culture systems, and thefinishing and packaging systems subset(s) of the pharmaceuticalmanufacturing process whereby the data compiled by the subset processesis tracked continuously overtime and said data is used to analyze thesubset processes and whereby said data is integrated and used to analyzethe quality control process of the pharmaceutical manufacturing processat-large.

The nanomaterial analyzes substances, providing a 3-D visualization tocharacterize morphology, texture, or roughness which could indicatecontamination or similarly an out of specification active or passiveingredient. (See FIG. 5).

In one embodiment, the monitoring and tribo-technical analysis achievesa step of integration into a manufacturing execution system wherebymanufacturing productivity and product quality are increased. Costs arestreamlined over time.

Example 8 Methods of Performing a Porosity/Permeability/VisualizationAnalysis

The nanomaterial is integrated into a pharmaceutical manufacturingsystem to perform a porosity, permeability, or visualization analysis.It will be understood by one of skill in the art that the computerproduct integrates the hardware via generally understood devices in theart (i.e. attached to the analog device via an analog to digitalconverter, wireless means, etc.).

The porosity and permeability analysis provides for the monitoring ofpharmaceutical manufacturing wherein the ingredients can be measured andre-routed within the specific process (i.e. powder blending,liquid-solid filtering, gas-liquid purification, etc). See FIG. 6. Thevisualization analysis is used to monitor quality parameters such assurface roughness of a final product (i.e. scanning a tablet for cracksor surface deviations outside the quality parameters).

The invention further comprises implementation of the porosity,permeability, and visualization analysis into the crystallizationprocess, the tablet press process, the chromatography process, the pHmonitoring process, the liquid mixing process, the powder blendingprocess, the water-for-injection systems, the water purificationsystems, the cell culture systems, and the finishing and packagingsystems subset(s) of the pharmaceutical manufacturing process wherebythe data compiled by the subset processes is tracked continuouslyovertime and said data is used to analyze the subset processes andwhereby said data is integrated and used to analyze the quality controlprocess of the pharmaceutical manufacturing process at-large.

In one embodiment, the monitoring and porosity, permeability, andvisualization analysis achieves a step of integration into amanufacturing execution system whereby manufacturing productivity andproduct quality are increased. Costs are streamlined over time.

Example 9 Methods of Interfacing Nanomaterial in Downstream ProcessingSystems

In the scope of the invention, downstream processing refers to therecovery and purification of biosynthetic products, particularlypharmaceuticals, from natural sources such as animal or plant tissue orfermentation broth, including the recycling of salvageable componentsand the proper treatment and disposal of waste. It is an essential stepin the manufacture of pharmaceuticals such as antibiotics, hormones,antibodies, and vaccines. Downstream processing and analyticalbioseparation both refer to the separation or purification of biologicalproducts, but at different scales of operation and for differentpurposes. Downstream processing implies manufacture of a purifiedproduct fit for a specific use, generally in marketable quantities,while analytical bioseparation refers to purification for the solepurpose of measuring a component or components of a mixture, and maydeal with sample sizes as small as a single cell. It is understood inthe art that downstream processing operations are divided into fourgroups which are applied in order to bring a product from its naturalstate as a component of a tissue, cell or fermentation broth throughprogressive improvements in purity and concentration.

Step 1: Removal of Insolubles

This first step and involves the capture of the product as a solute in aparticulate-free liquid, for example the separation of cells, celldebris, or other particulate matter from fermentation broth containingan antibiotic. Typical operations to achieve this are filtration,centrifugation, sedimentation, flocculation, electro-precipitation, andgravity settling. Additional operations such as grinding,homogenization, or leaching, required to recover products from solidsources such as plant and animal tissues, are usually included in thisgroup. The nanomaterial is integrated into step 1 according to thepresent invention.

Step 2: Product Isolation

The second step is removal of those components whose properties varysubstantially from that of the desired product. Generally, water is thechief impurity and isolation steps are designed to remove most of it,reducing the volume of material to be handled and concentrating theproduct. Solvent extraction, adsorption, ultrafiltration, andprecipitation are some of the operations involved. The nanomaterial isintegrated into step 2 according to the present invention.

Step 3: Product Purification

The third step is done to separate those contaminants that resemble theproduct very closely in physical and chemical properties. Thenanomaterials of the present invention are utilized heavily in step 3due to the ability to deliver precise measurements at the nanoscale.This stage contributes a significant fraction of the entire downstreamprocessing expenditure in terms of cost. Examples of operations includeaffinity, size exclusion and reversed phase chromatography,crystallization, and fractional precipitation. The nanomaterial isintegrated into step 3 according to the present invention.

Step 4: Product Polishing

The final processing step which ends with packaging of the product in aform that is stable, easily transportable and convenient.Crystallization, desiccation, lyophilization and spray drying aretypical operations. Depending on the product and its intended use,polishing may also include operations to sterilize the product andremove or deactivate trace contaminants which might compromise productsafety. Such operations might include the removal of viruses ordepyrogenation. The nanomaterial is integrated into step 4 according tothe present invention. The nanomaterial or a plurality of nanomaterialsdisclosed herein are designed via bottom-up design whereby thenanomaterial is designed with a particular functionality. It will beunderstood by one of skill in the art that the functionality isdetermined by the pharmaceutical manufacturing process that is beinganalyzed. The nanomaterial is loaded with an electrical circuit with anI/O interface. Additionally, the software program, computer readablecode, and methods disclosed herein are designed by standard methodsusing a top-down design approach to programming. The software program isinterfaced with the functional nanomaterial via the circuit.

The interfaced nanomaterial is used to execute or monitor a downstreamprocess. (See FIG. 7).

In one embodiment, the integration of the nanomaterial into a downstreamprocess achieves a step of integration into a manufacturing executionsystem whereby manufacturing productivity and product quality areincreased. Costs are streamlined over time.

The present invention is not to be limited in scope by the embodimentsdisclosed herein, which are intended as single illustrations ofindividual aspects of the invention, and any that are functionallyequivalent are within the scope of the invention. Various modificationsto the models and methods of the invention, in addition to thosedescribed herein, will become apparent to those skilled in the art fromthe foregoing description and teachings, and are similarly intended tofall within the scope of the invention. Such modifications or otherembodiments can be practiced without departing from the true scope andspirit of the invention.

1) A method comprising, a) establishing an acceptance criteria for aglycol manufacturing process; b) monitoring data generated by a deviceused in said glycol manufacturing process, wherein said device isoperably linked to a nanosensor; c) analyzing the data against theacceptance criteria; and d) determining whether the acceptance criteriais met to make a quality based assessment 2) The method of claim 1,wherein the device is a solvent recovery system. 3) The method of claim1, wherein the device is a pure water system. 4) The method of claim 1,wherein the device is a chromatography system. 5) The method of claim 1,wherein the analyzing is failure modes and effects analysis. 6) Themethod of claim 1, wherein the monitoring is continuous. 7) The methodof claim 1, further comprising maintaining the data over time to createa historic record. 8) A computer memory having computer executableinstructions to perform the method of claim
 1. 9) A kit comprising thecomputer memory having computer executable instructions of claim
 8. 10)A manufacturing execution system comprising, a) A computer memory havingcomputer executable instructions used to monitor a glycol manufacturingprocess; b) A nanosensor; c) An input/output device; d) A plurality ofhardware devices used of manufacture glycol. 11) The manufacturingexecution system of claim 10, wherein the hardware device is selectedfrom the group consisting of blenders, bio-reactors, capping machines,chromatography systems, dry heat sterilizers, freezers, fillingequipment, filtration systems, incubators, labelers, dryers, mixingtanks, modular cleanrooms, neutralization systems, process tanks,vessels, refrigerators, separation systems, specialty gas systems,solvent recovery systems, waste inactivation systems/“kill” systems,vial inspection systems, vial washers, water for injection (WFI)systems, and pure water systems. 12) The nanosensor of claim 10, whereinthe nanosensor is a biosensor. 13) The nanosensor of claim 10, whereinthe nanosensor is an optical sensor. 14) The nanosensor of claim 10,wherein the nanosensor is a chemical sensor. 15) The chemical sensor ofclaim 14, wherein the chemical sensor is selected from the groupconsisting of oxygen sensors (a.k.a. λ sensors), ion-selectiveelectrodes, pH glass electrodes, and redox electrodes. 16) Theinput/output device of claim 10, wherein the input/output device is aanalog to digital converter. 17) A kit comprising the manufacturingexecution system of claim 10.